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1Need Assessment Survey / Designclinics MSME / Bardoli blacksmith cluster / 2012

BLACKSMITHS OF BARDOLI

NEED ASSESSMENT SURVEYDESIGNCLINICS MSME

2012


PREFACE

The NAS (Need Assessment Survey) was conducted at Bardoli for the blacksmith cluster in 2012. The exercise covered 16 micro scale units making various agricultural imple-ments . The NAS focussed on collecting information about the manufacturing practises, problems and issues that the units face.

The methodology included: Questionnare based survey of manufacturing units, Inter-views with unit owners & employees, Observation of process and workplace, Market visit to dealers and stockists.

The objective of the information collection was to identtfy specifc design opportunities that would help in the revival of the cluster.

The NAS focussed onRaw Material at different stages of manufacturing Infrastructure setup and work stations Skill and techniques, FinishesProduct form, shape and usageTools and technology Capability of manufacturing units Present Market status Current Competition Packaging, logistic and storage

Expected DeliverablesThe expected outcome of the need assessment survey is to be able to generate precise and indepth data on the products, processes and practices in the cluster. It seeks to idenify product related issues, process related problems and other critical parameters related to distribution, packaging and marketing of the finished products.


ACKNOWLEDGEMENTS

My deepest acknowledgements to all the people who contributed and facilitated the need assessment survey at Bardoli.

My sincere thanks to:

Shri Ram Kumar singh and Mrs. Rama Singh, who have dedicated their lives to the uplift-ment of this cluster

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All the owners of the MSME units interviewed who welcomed us with great hospitality

Shri Pradyumna Vyas, Director, National Institute of Design Shashank Mehta, Chairperson, MSME DesignclinicsNID MSME Designclinics team Ahmedabad

All employees of the Suruchi Sakshat Vasahat Trust


DESIGNCLINICS SCHEME

Design Clinic Scheme for Design Expertise to MSMEs, a unique and ambitious design

intervention scheme for the country’s large micro, small and medium scale enterprises,

is an initiative of Ministry of MSME, Government of India has been launched under

National Manufacturing Competitiveness programme. The main objective of the Design

Clinic Scheme is to bring MS&ME sector and design expertise into a common platform

and to provide expert advice and solutions on real time design problems, resulting in

continuous improvement and value addition for existing products.

This model brings design exposure to the door step of industry clusters for design aware-

ness, improvement, evaluation, analysis and design related intervention. Design clinic

scheme will assist industrial clusters to open a channel for design information inflow for

creative, innovative and futuristic approach towards the product, process, operations,

manufacturing and business design. The scheme will help generate insight for opportu-

nity identification and design intervention for competitive and break through solutions for

MSMEs.

The National Institute of Design, Ahmedabad, has been setup as the nodal agency for

the scheme. With its rich experience in design training and consultancy, NID will act as

matchmaker to the MSMEs and design professionals. It shall also administer effective

implementation of the plan. This report summarizes the findings of the NAS attempting

to identify the design opportunities, which would help in the upgradation of the cluster.

Design sensitization seminars (Phase 1), need assessment surveys & design awareness

programme (phase 2) and design projects (Phase 3) will help MSMEs in various stages

to develop competitiveness.


1.0 Cluster Information


1.1 Location

Bardoli is a city and a municipality in Surat Metropolitan Region in the state of Gujarat, India. Bardoli is the east most end of the Metropolis of Surat Bardoli is one of the primary Satellite Towns of Surat Metropolitan Region. It is said that Bardoli is the Paris of India. Bardoli is located at 21.12°N 73.12°E.[1] It has an average elevation of 22 metres (72 feet).Bardoli is also the center for most of the Talukas or Counties in South Gujarat. Due to its central location for many Talukas it is a major economic centre of Surat Metropolis. The Satya-grah movement was started by Sardar Vallabhbhai Patel All the details of the Satyagrah with photos are now conserved in the “Sardar Patel Museum”. This Place is middle of bardoli town on station road.

As of 2001 India census,[2] Bardoli had a population of 51,963. Males constitute 51% of the population and females 49%. Bardoli has an average literacy rate of 74%, higher than the national average of 59.5%; with 54% of the males and 46% of females literate. 9% of the population is under 6 years of age.

Bardoli, long ago nothing but a very small village, is populated due to the establishment of “Bardoli Sugar Factory”. It is presently, the largest sugar factory in Asia. It also has largest number of used car dealers in Gujarat. This is because the Bardoli region is home to a large number of Non-Resident Indians, who visit Bardoli once a year in December, buy a car and later on sell it when they leave.

The region of south gujarat, specifically the surroundings of the dangs district, area south of river ambika, whole of dangs district, part of valsad district (excluding navsari and gandavi talukas), part of surat district (valod, vyara, uchchhal, songadh and mahuva receive an average rainfall of 1500 mm and more. The region is predominantly agricultural, with the soil (deep black with few patches of coastal alluvial, laterite and medium black soils) and is cultivated mainly with cotton, jowar, paddy, vegetables, horticultural corps, sugarcane and millet.


1.3 History of blacksmithy

Rural blacksmiths are traditional artisans ho still play a very important role in the ru-ral economy. Traditionally, they have been producing agricultural equipment such as sickle, hoes, crowbars, plough, spades etc along with other implements of domestic use. Villages still depend a lot on these traditional blacksmiths and despite technological im-provements taking place in the industrial mode of factory type production of blacksmithy products. This is also true that most of these blacksmiths have not benefitted by techni-cal and financial assistance through government or non governmental efforts and they still work with age old technologies. At the same time they are still surviving because they provide products and services which are essential for day to day living and they are present everywhere whether it is a town or a remote village. Therefore it is essential to preserve, promote and support blacksmiths, who can in future play a key role in rural industrialization.

In the early civilization days, people used tools of stone, wood, bone and horn. Later on, with the advent of agriculture, use of copper and bronze started. The excavation of the Indus valley civilisation indicates the use of copper and bronze during 2600-1600 BC. Iron was the next discovery and finds a reference in the Yajurveda. Vedic texts of satpad Barmhanas also refer to the use of iron. All the references indicate that by 700 BC the use of iron had become common in agriculture. Iron axes, plough shares and other tools helped clear the dense jungles and make them habitable and cultivable.

The Vedas contain references to various metal objects such as bow and arrow, swords, spears, javelins, lance, hatchets and discus. There are numerous references to iron in protective armour of warriors.

The Mauryan period (320-180 BC) was the period when townships came into existence. A tremendous growth in mining and metallurgy along with artisan activities such as smelting and forging took place during the period. During the Kusanas and Satvahanas blacksmiths enjoyed tremendous status and prosperity. Iron was exported to the African coast through Gulf of Cambay. The iron pillar at Qutub Minar in Delhi was erected in 400 AD and the quality of iron working is evident from the fact that the pillar has no sign of rust yet. It is recorded that the Dutch began the export of iron products from Coro-mandel to Batavia, the volume of which was incredibly high.

During the Mughal period, blacksmiths were divided into two categories: those catering to the market who worked in the imperial karkhanas making mainly weapons, settled in cluster form in and around Nagars and those tied to the village communities and served their daily needs related to agriculture and allied requirements.

British technology which invented furnaces, led to a substitution of indigenous iron with imported iron in the early 18th century. Thus imports of English goods wiped out parts of the domestic iron industry. Armament for blacksmiths supplied huge production of swords, guns was also replaced by western guns. Thus began the decline of the black-smiths.


The cluster today

Blacksmiths in Gujarat belong to mainly 2 communities - Panchals who are the tradi-tional blackmith caste and tribals who have adopted the trade. In the blacksmith clsuter at Bardoli, bothe the communities have been reached out to and documentaed.

The focus in not caste based, rather, the development of the trade in the geographical spread. in a diagnostic study of 132 families, it is revealed that:

Family size: 1-3 members - 28.78%4-6 members - 56.82%7-10 members - 12.88%

Employment wise:Number of families - 132Total number in 132 families - 617Working members - 268Engaged in blacksmithy - 190Engagend in other professions - 78 (agriculture -59, jobs - 19)

Blacksmiths who are more than 30 million in numbers today are facing an unfortunate situation, as even after six decades of independence, their conditions continues to decline. This proud and respected community is today fighting for a survival. Many have given up and moved away from their traditional occupation. They have been deprived of the benefits and facilities, which would have enabled them to move with time and adapt new skills, technologies to consolidate their position in society. They are not finding comfortable space in the new economic and industrial order. The powerful marketing machinery supports market for other goods at the cost of artisan goods. The ongoing research and development efforts are oriented towards developing capital intensive pro-cesses and technologies which adversely affect the rural blacksmithy sector.

Some of the key observations from the sector are:

1. All the surveyed units and individual blacksmiths use mostly manual methods of forg-ing. Forging is a labor intensive processes.

2. All units use the age old primitive method of production.


3. The quality of output is most of the time crude and of inconsistent quality.

4. Except one unit, all other surveyed units had low volume production and made prod-ucts for local consumption only.

5. Market exposure is minimal, but the manufacturers exhibit tremendous knowledge about the local requirements and conditions. Every unit’s products look the same and the blacksmith claims to recognise his work by sight.

6. Similar looking products available in all surveyed markets as most units produce same or similar products, sells in the same markets/dealers

7. No appropriate process of costing followed. The cost is mainly calculated as a single purchase cost of the implement and at the same time, they charge money to sharpen the tools. This keeps inflow of money, however petty.

8. No consistency in prices between vendor to vendor, no one sticks to prices, in a way no standard price for products.

9. There is a complete lack of product standardisation, with each blacksmith using his skill levels to achieve the product finishes. The knowledge of size and shape is however traditional and the local populace resents and resists change in design.

10. The current products such as sickles, axes etc are suitable for batch production, low production capacity only. This is also largely season dependent, depending on the crop that is currently sowed.

11. Work environment, workstation and ergonomic seating are major areas of concern in all units surveyed. The main problems include inhalation of smoke from the coal fire, improper working postures, lack of ergonomic handtools, usage of heavy forging hammer all contribute to musco skeletal stress. Almost all units reported back pain, upper arm fatigue and drop in productivity.

12. Unavailability of workers, skilled workers is a serious concern for the larger units. there also seems to be a cultural bias between the two communities. The Panchals believe the tribals to be waywards and unreliable. The tribals, who have adopted this occupation are not completely committed as they vary between agriculture, menial jobs and blacksmithy

13. The younger generation is not attracted to the profession due the vagaries in the busi-ness. They prefer to undertake employment in the nearby sugar factory.


2.0Products, Processes


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Redesign of handles according to ergonomic principlesUse of cultural motifs which cannot be machine made is a good way of branding

Products made by cluster

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The region of south gujarat, specifically the surroundings of the dangs district, area south of river ambika, whole of dangs district, part of val-sad district (excluding navsari and gandavi talukas), part of surat district (valod, vyara, uchchhal, songadh and mahuva receive an average rainfall of 1500 mm and more. The region is predominantly agricultural, with the soil (deep black with few patches of coastal alluvial, laterite and medium black soils) and is cultivated mainly with cotton, jowar, paddy, vegetables, horticultural corps, sugarcane and millet.

The blacksmith community is involved in manufacture of agricultural implements of all shapes and sizes, ranging from simple hand held imple-ments to fitments and accssories for tractors and heavy agri machinery.

The main products of the cluster include:1. Sickle (Datarna / Datarni) classified on basis of size, curvature and crest for slicing of stems2. Axes (Classified on basis of size of head and handle)3. 4. Digging hoes5. Sugarcane stem cutters6. Furrow attachment for tractor7.8. Bill hook for branch trimming9. Plough10. Hand hoe11. Four pronged digging hoe12. Hand hoe13. Three pronged digging hoe14. Two pronged digging hoe15. Rake16. Seeder17.


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Fit and finishing of the product need improvement

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ANVIL ‘YERAN’

COAL STORAGE‘KOLSA’

WATER TROUGH

ANVILCOAL FURNACE

CLAMPS‘CHIMTA’

HAMMER‘HATHODI’

Production Process / Tools Design of smoke free furnaces / furnaces which can be hermetically controlled / furnaces with alternate energy sources other than coal

Design of ergonomic “chimta” or clamps is necessary. Currently used clamps are basic, rudimentary and un-productive

A blacksmith uses several different types of tools to forge metal into the desired shape. The most basic implements are:

1. The coal furnace is a simple mud and brick construction that is covered from 4 sides leaving the mouth open to put the metal blank in.

Main issue: Smoke generated from coal is inhaled by the blacksmith which leads to severe respiratory illnesses especially from constant inhalation of carbon monoxide. Coal is increasingly getting difficult to procure. There are 2 sources of coal for the blacksmith - coal from forest wood and coal from illegal alcohol brewing that happens in the forest areas. The forest coal is expensive and difficult to get as the forest department keeps a tight vigil on the illegal felling of forest wood. The coal from alcohol pits are considered best for higher calorific value and is cheaper to procure. How-ever blacksmiths have to procure this illegally, often smuggling it through police lines on the district borders.

OPPORTUNITYDesign of furnaces that can regulate smokeDesign of furnaces that could alternate sources of energy

2. Clamps of different sizes are used to clamp and hold the hot metal. Main issue: Most of these clamps are locally made, of rudimentary con-struction and quality. The tools are unergonomic and are copies of old designs that have not changed from several decades.

OPPORTUNITYDesign of ergonomic clamps of superior build and qualityDesign of furnaces that could alternate sources of energy


Design of better anvils which improves finish & pro-ductivity

Design of ergonomic hammers can improve produc-tivity & improve output

As comared to the TATA brand hammers, this design from Maharashtra gives better results and life

Specific files can be developed with ergonomic han-dles for productivity enhancement

Manual blowers with ergonomic handles and single handed operation is a huge advantage

Design of a jig that could hold the blade of the sickles and axes is a strong and immediate requirement

3. Anvil is a block of solid steel that is tempered at a very high tempera-ture. This make is extremely hard and this is used a base for all hammer-ing. It is called ‘yeran’ in the local lingua.

Main issue: Anvils are locally made, of rudimentary construction and quality. The build quality of the anvil results in better or bad finish of the final products made by the blacksmith. If the anvil breaks, it is a compli-cated process to redo the head of the anvil. The cost of an anvil ranges from 2500-3000 Rupees. This is expensive by local standards. Trainee and amateur blacksmiths often buy second hand anvils to start with.

4. A variety of hammers are used to hammer the hot metal into shape. primarily based on head size, these are called hothoda / hathodi in local lingua. There are 2 kinds of hammers available : TATA make and a lo-cal design that is sourced from Maharashtra. The TATA brand hammer is a generic hammer which is used in different hammering jobs whereas the Maharashtra design is a dedicated forging hammer with broader and flatter head. This hammer is not available in local markets. A few select blacksmiths have access to this and this is not shared by the blacksmiths in Maharashtra.

5. A variety of hand files are used to finish the forged piece. These include rough files for descaling, and fine files for polishing.

OPPORTUNITYDesign of forging hammers & hand files with ergonomic handles which would reduce the physical stress leading to higher productivity.

6. A T shaped jig is used to balance the job while filing. The anatomical position of the artisan is very awkward, as he has to balance the jig with his thigh and a clamp with his feet. A suitable design to address this im-mediate need would be instrumental in improving productivity immedi-ately.

OPPORTUNITY


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Design of jig as per anthropometric and body angles.MANUFACTURING PROCESS

A sickle undergoes a 20 step activity before it is finally sold to a end user.

Image 1: The furnace is lit with a handful of coal and once the coals glow, more and more is added to raise the temperature of the furnace.

Image 2: A rod or strip of mild steel is heated till it is read hot. In this malle-able state the metal is ready to take whatever shape the blacksmith want to give it.

Image 3: Placing the hot strip on the anvil, the blacksmith beats the metal into shape.

Image 4: The process of heating - shaping is repeated endlessly until the desired share has been achieved.

Main issues

1. The temperature of the furnace is not conrollable. The balcksmith has to rely on exprience to get the combination of material and temperature cor-rect.This hasa direct result on the finishing of the implement. Every cutting im-plement degrades over time and usage and has to be sharpened.

2. Crouched working posotion causes extreme back pain. Added to it, low seating and heavy hammers cause physical strain.

3. An unorganised workspace adds to repetitive motion strass, where the blacksmith has to twist several times to reach the instruments.


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Image 5: The handle is used as a template to achieve dimensional coher-ence. The metal is reshaped until it is accurate.

Image 6, 7: While hot, the metal piece is inserted into the wooden handle. and hammered into place.

Image 8, 9: The forged metal is then quenched in a trough of water. This sudden drop in temperature causes the metal to harden, which is a desir-able property of a cutting tool such as a sickle or axe.

Main issues

1. Badly designed and locally made clamps are extensively used. These cause extreme distress in terms of wrist and hand pains, which all sur-veyed blacksmiths reported. The incidence of injuries were high for trainee blacksmiths. Injuries and constant pain result in decreased productivity.

2. Constant inhalation of smoke from the burning furnace causes severe respiratory illnesses in most blacksmiths. Due to lack of medical facilities in the area, the problem could lead to compromised immunity and finally - tuberculosis.

3. The workstation or place of usage has to be designed according to the zone of reaching, such that repetitive tasks are placed closer to the black-smith. This causes reduction in fatigue and less wasteful motion.


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Image 10, 11, 12: Using a hand file the surface abrasions are removed.

Image 11: The cutting edge of the tool is sharpened using a fine file

Main issues

1. Lack of ergonnomic hand tools is another area which causes loss in productivity and added fatigue.


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Image 13, 14, 15, 16: The cutting edge of the blade is notched with tiny ridges. This increases the cutting power of the tool several fold and adds an aesthetic appearance to the tool.

Main issues

1. There is an immediate and pressing need to design some jigs and fix-tures that can alleviate the wrong working postures of the blacksmiths. In the absence of any, the blacksmiths use a combination of both feet and their arms to file the metal. This is completely unergonomic and the strain can be reduced with a designed, low cost jig.


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Image 18, 19: At the end of all iterations, finally the toll is heated again and oil is applied using a broad brush, to the cutting edge. This act permanent-ly arrests the deformation of the metal and strengthens the edge further.

Image 20: The final product.

Main issues

1. The handle of the implement has a great role to play in the success in adaption by local populace, who are used to age old designs that have not changed since generations. The handle and the blade has to be ‘balanced’ such that handling the tool is easy. The handle also has to be designed in way that facilitates usage, safety and carrying it around.

2. Competition from factory made implements is a serious possibility in the coming years, specifically implements from China. Though the black-smiths today are enjoying a revival, given the fact that most of their pro-duce is consumed in local markets, the threat of machine made, uniform finish implements looms large. The blacksmiths could look at oranmenta-tion of cultural motifs on the handles that would not only increase the per-ceived value of the product, but also elevated the design from a ubiquitous product to a cultural design.


3.0Design audit


Constant twisting to reach wooden handles

Hard seating leads to discomfort

Anvil and tools at a lower height in unergonomic work postures

Anvil placed at an extended lengthcausing lower lumbar stress

Mukeshbhai Panchal

Mukeshbhai Panchal Is a resident of Jamaniya, Taluka Valo, Zilla Tapi, Gujarat. Mukeshbhai inherited the business from his father and he has been involved with the shop as long as he can remember.

The main product range includes agricultural implements such as sickles, hoes, axes etc. He however also supplements his business by fabrication of grills, body repairing of tractors, treshers. His main activities are blacksmithy and welding.

Mukeshbhai’s annual turnover is 6 lac rupees. His shop is 50X45’ and has cutting machine, welding machine, drill and bending machines in his shop. He employes 4 people besides himself.

Main Isuues:

The agricultural implements have not changed in hundrerds of years. They con-tinue to made the same way, with no innovation or change whatsoever.

Mukeshbhai buys steel from Gujarat Steel, a dealer. The maximum assertion of quality of steel is through visual inspection only.

The seating near the furnace is extremely low which causes severe discomfort. The pain through long hours of working is localised in the lower back and shoul-ders. This has caused a drop in output.

There is no branding or promotion of name whatsoever. Having a branding cou-pled with good quality can improve sales.

There is zero interaction with other clusters or training. Training is often on the job.

Product development: Given the large space available, Mukeshbhai could look at large agricultural implements such as grain separators.


Currently the fabrication products are displayed on the innermost wall of the shop. There is a huge open space in front of the shop which could be used for display.

Product design intervention could focus of design of ergo-nomic handles for most agri implements. There is also scope for branding which could help the unit.

Lack of safety equipment during weldingleads to eye problems and blidness

Unergonomic postures for welding

Rigid, hard seating will lead to spinal problems

Visibility and placement is-sues Relocation of welding ma-

chine repeatedly

The wokspace inside the shop is extremely cluttered. Reorganising the space would offer more productive workspace as well as opportunity for storage.

Placement at lower heights which is unergo-nomic, leads to fatigue and low productivity

Electrical hazard

Haphazard placements of items in the workspace leads to overall loss of productivity

Naked electrical wires are a safety hazard

Proposed interventions

Design of the layout of the workshop as per space design principles to facilitate storage, production and materail han-dling with ease. The area for cblacksmithy and other activities could be redefinesd with spatial differentiation.

Assistance with New Product Development of agricultural machinery with a focus of technical design, industrial design, product standardization, value engineering, branding

Design of display and promotional collaterals in front of shop.


Main design intervention would be to design and build a workstation according to ergonomic principles, which focus on placement of spaces which causes least physical stress to the user.

Placement of quenching pot iin wrong position, leading to twisting of back constantly

Clutter in workspace

Clutter in workspace

Ungrouted anvil leads to vibration and shock in fore and upper arms, leading to fatigue

Ishwarbhai Panchal

Ishwarbhai Panchal Is a resident of Kanolpada, taluka Vasada, Zilla Navsari, Gujarat.

The main product range includes agricultural implements such as sickles, hoes, spades, plower, deweeder, axes etc. His main activities are blacksmithy and welding. Mukeshbhai’s annual turnover is 50,000 rupees. His small shop is rented’ and has cutting machine, welding machine, drill and grinding machines in his shop. He and his son run the shop.

As the design, Ishwarbhai states that from area to area, the design of the agri-cultural implements change. This is due to the different crops that are reaped and the usage patterns thus.

The shop is small and stuffy especially with the smaoke from the coal furnace. Ishwarbhai complains of tremendous back and knee pain and admits that this has affected productivity.

In an effort to increase sales, ishwarbhai has used the inner back wall of the shop to build a diasplay stands to arrange and demonstrate products for sale. He admits that this has helped in sales. Forn a typical process, Ishwarbhai procures steel from Vasad steel which is 10 km away in the form of 11” strips. The wooden handles for the implements are sourced from local carpeneters who cater to all the blacksmiths ion the area.

Main Isuues:

The shop is very dimply lit and claustrophobic. This causes discomfort.Like most blacksmiths in the area, Ishwarbhai’s layout around the kiln is haphaz-ard and unergonomic. He confesses to extreme back and knee pain during work.

Lack of safety equipment whilst using welding was observed and documented. This could lead to loss of vision and other vision disorders in the near future.

His training and exposure is limited to his ongoing actvities with Suruchi Sakshat Vasahat Trust. He wishes that the products be displayed in a shop.

Product finishes need major improvement.


Extreme low lighting inside the shop causes severe issues in visibility. Added to it is smoke from the furnace which makes the working conditions quite dreary


Open coal furnaces causes inhala-tion of carbon monoxide and CO2, leading to im paired respiratory function Lack of safety equipment during welding

leads to eye problems and blindness



Design of the layout of the workshop as per space design principles to facilitate storage, production and materail handling with ease. The area for cblacksmithy and other activities could be redefinesd with spatial differentiation.

Design of welding rigs

Assistance with New Product Development of agricultural machinery with a focus of technical design, industrial design, product standardization, value engi-neering, branding



Organised storage and display in the shop

No proper storage of coal

Naked wires are a fine and health hazard

Naked wires are a fine and health hazard

Ashwinbhai Panchal

Ashwinbhai Panchal owns and runs Varsha welding works and resides in Khamla Jahapa, Vasada, Zilla Navsari, Gujarat.

The main product range includes agricultural implements such as sickles, hoes, spades, plower, deweeder, axes etc. His main activities are blacksmithy and welding. The annual turnover is 3 - 4 lac rupees.

His main activity is sourcing not manufacturing. He sources good products from nearby small artisans and sells them in his shop. Since manufacturing forms a very small piece of his profile, the workstation is relegated into one corner and in an ignored state.

The designs of the products are per age old atandards and are modified as per the requirements of the villagers.

The innovation in Ashwinbhai’s approach is to mix welding and forging wherein the rigs to grip the handle are separately made and welded to the cutting head.

The main mode of marketing is the weekly market that is set up in the area on fridays. the display is done on a table with the instruments laid out.

Main Isuues:

The shop is very dimply lit and claustrophobic. This causes discomfort.

There is no branding or logo, making the product indistuingishable from several others.

There is no display in front of the shop including name boards, which makes the shop hidden amongst several others who do the same buisiness.

The seating for the furnace is cramped and in one corner which causes tremen-dous discomfort.No branding / displays


Cramped working space

Cluttered layout of the shop

Low level placement of welding station leading to unergonomic working postures

Improved product finishes are needed


Designed exhaust for the coal fumes is a postive design feature

Ungrouted anvil leads to shock and vibrations in arms, leading to fatigue

Clutter and unorganised workspace leading to loss of precious space

Jayantibhai Panchal

Ashwinbhai Panchal owns and runs Mahakali welding works and resides in Khamla Jahapa, Vasada, Zilla Navsari, Gujarat.

The main product range includes agricultural implements such as sickles, hoes, spades, plougher, de weeder, axes and is currently involved in building a custom designed grain separator etc. His main activities are blacksmithy and welding. The annual turnover is 2 lac rupees.

Jayantibhai is a very innovative person with a sound understanding of mechani-cal engineering fundamentals. Though not formally educated, his ability to design and develop machinery for specific tasks is widely known and recognised in the area.

He was the innovator and builder of the mechanical forge, a machine that com-pletely resolved the manual and laborious method of hammering into a mechani-cal powered system. He is also credited with the ingenious development of the grain separator with blower that allows for separation of grain from husk. His initial prototypes have been very successful and he has several enquiries. How-ever, his problem is finance as the government or banks are unwilling to help.

Jayantibhai suffers from back and knee pain.

His understanding of human factors related issues also comes to the fore as he has innovated to raise the anvil and the kiln. He has also built chimneys that chan-nel the smoke away into the atmosphere thereby offering much better condition of work.

Jayantibhai wants to quit blacksmthy and focus completely on new product development of agricultural machinery.

Main Isuues:

The reorganisation of the shop would allow more space to be effectively utilized. The shop could be redesigned with ergonomic and space related principles.

The current seating at the kiln and anvil is crude. This needs to be redesigned.


Clutter and unorganised workspace leading to loss of precious space

Clutter and unorganised workspace could be a fire hazard






Dipeshbhai Panchal

Dipeshbhai Panchal owns and runs Balaji and Works in headpost Unnai, Taluka Vansda, Zilla Navsari Gujarat. His product range includes all agricultural instru-ments like axes, sickles etc but his speciality is spades of all kinds. He employs 3 people too work for him and generates Rs.3 lac annually.

Dipeshbhai claims an innovation to his credit, which he says has differentiated him from all competitiors. He has figured out a technique to use a metal pipe in-stead of the wooden handle. He is well known for this work in surrounding areas and he claims less breakage because of this design.

He has alos innovate the sugarcane cutter, a chopper blade that chops the knots of a sugarcane stalk. This has been a success in the area as south gujarat is a major sugarcane growing area.

The workshop is extremely cluttered and claustrophobic. The workshop is also a makeshift garage and the level of illumination is very low.

His interactions with other clusters is limited to SSVT, Bardoli Sangh and Navsari based organisations.

Main Isuues:

The reorganisation of the shop would allow more space to be effectively utilized. The shop could be redesigned with ergonomic and space related principles.

The current seating at the kiln and anvil is crude. This needs to be redesigned.

He gets no technical assiatnce and his efforts are often trial and error.

Lack of ventilation

Haphazard dumping

Low workstations


Low workstations

Hard seating leads to fatigue and back problems

Placement of quenching pot leads to twisting of back

Placement of coal leads to twisting of back

Handle size and shape is not as per good ergonomic principles

Open coal furnaces causes inhala-tion of carbon monoxide and CO2, leading to im paired respiratory function

Handle size and shape is not as per good ergonomic principles

Product finish has to beimproved substantially






Low workstation leading to fatigue

Kishanbhai Gamit

Dipeshbhai Panchal owns and runs Balaji and Works in headpost Unnai, Taluka VKishenbhai Mandabhai Gamit is a native of Khet Aujar, Bartad road, Unnai, Navsari, Gujarat. He runs his unit in the front porch of his house. He makes all kinds of sickles, hoes, rakes, and commonly used agricultural instruments.

He does not own a welding machine and his work profile is limited to black-smithy. His annual turnover is Rs.50,000 and employs 7 people including himself and his son.

Kishanbhai has a lot of space as the porch is very spacious. Hence the placement of the furnace and seating does not look cramped. However the seating is low and this causes ergonomic issues.

His display of wares is limited to spreading the manufactured products on the ground on a sheet. There is no branding as such either in the form of logos or trademenrks or product differentiation.

He has established contact with the Netran cluster in Bharuch which allows him to procure as well as sell.

He has an immense problem in the procurement of coal as coal is a dwindling re-source. He has to ilegally obtain coal from the nearby forest and this often invites the ire of the forest offcials who try to prevent the felling of trees for firewood and coal.

Main Isuues:

Availability of coal

Product finishing need to be improved.

Redesign of the furnace and seating at a raised height to facilitate production as per ergonomic principles.



Proposed design interventions

Redesigned workstations with raised seating and anvil

Product development of simple instruments

Display stands for display on the porch

Name board / Branding


Haphazard placement of welding machine

Old disued machined piled up, occupying space

Dilapitated shed which causes rains to seep in during monsoons

Dumping of tools and other imple-ments in an unorganised manner

Manojbhai Panchal

Manoj Kumar Ramabhai Panchal is the owner of Shivkrupa Works, located at Mukampost Sealdah, Zilla Tapi, Taluk Valod Gujarat. He has been independently managing this small unit singlehandedly for 10 years. He has trained for 30 years with his uncle. His main work lies in blacksmithy (repair of instruments), grill fab-rication and other small fabrication jobs.

His main line of manufacturing includes axes, sickels, plougher and other small agricultural instruments.

The infrastructure setup consists of a mini hammer, grinder, welding machine, drill, hand tools. The total prouction capacity is 2000 pieces per annum. The annual turnover is 60,000 rupees. Manojbhai’s main markets are in Bardoli and Mandu.

The market exists for repair and refurbishmnent, and not new products, accord-ing to him. Since most of th scrap is reused to repair existing instruments an agricultural implements, wastage is minimal.

Main Isuues:

Availability of coal



Clutter, unrorganised workspace


Complete clutter in the worrkspace which does not provide efficuent use

of space or storage



Redesign of workspace layout


Display stands for display on the road outside the shop



Kalpeshbhai Panchal

Kalpeshbhai Manharbhai Panchal owns and operates Ambika Welding Works in Lohar Fadia, mukam post sealdah, district Tapi, Gujarat.

His main line of manufacturing includes axes, sickels, small agricultural instru-ments. grills, doors, shed fabrication, electric clamps (Kamala Clamps) and aslo fabricates the mini forge occassionaly.

The infrastructure setup consists of a mini hammer, grinder, welding machine, drill, hand tools. The unit employs 3 people including himself. The advantage that Kalpeshbhai has is the huge space available to him. However most of this space is not used and the brick structures (in pic) are in a bad, dilapidated stage.

The annual turnover is 80,000 rupees. Kalpeshbhai’s products are for local con-sumption and sells them from his house.

Branding is absent, but uses KP on the clamps that he manufactures.

Main Isuues:

Availability of coal is a serious issue as the coal has to be sourced from the illegal liqour dens in the nearby forests. The cost of col has gone upto Rs.170 per sack.










Product design help for the design of miniforge for various applications


Raised seating for helper is good, helps in reducing fatigue

Fabricated display stand is good

Dilipbhai Panchal

Kalpeshbhai Manharbhai Panchal owns and operates Ambika Welding Works in Lohar Fadia, mukam post sealdah, district Tapi, Gujarat.

His main line of manufacturing includes axes, sickels, small agricultural instru-ments. grills, doors, shed fabrication, electric clamps (Kamala Clamps) and aslo fabricates the mini forge occassionaly.

The infrastructure setup consists of a mini hammer, grinder, welding machine, drill, hand tools. The unit employs 3 people including himself. The advantage that Kalpeshbhai has is the huge space available to him. However most of this space is not used and the brick structures (in pic) are in a bad, dilapidated stage.

The annual turnover is 80,000 rupees. Kalpeshbhai’s products are for local con-sumption and sells them from his house.

Branding is absent, but uses KP on the clamps that he manufactures.

Main Isuues:

Availability of coal is a serious issue as the coal has to be sourced from the illegal liqour dens in the nearby forests. The cost of col has gone upto Rs.170 per sack.




Good display stands

Safety principles followed

Low workstations and crouched positions reduces productivity by fatigue



Ackward working postures cause long term occupational injuries rseulting in severe back pain


Vasantbhai Kokani

Chinubhai Guljibhai Dabke is a resident of Mukam post Jarada, Taluka Ahwa, Zilla Dang, Gujarat.

He is a tribal who belonged to a family which practised agriculture for a living. His father is a farmer. Sonirao became a blacksmith as a means of steady income in lean periods of agriculture. He started with no formal training and has been a practising blackmith for 7 years. Chinubhai was helped by the Suruchi trust, Vagai trust and he was greatly assisted by the government subsidy which allowed him to procure basic tools of the trade.

Chinubhai retails his wares in the saturday market & his annual turnover is around 50,000 a year.

He normally makes sickels, axes and other small cutting instruments, and he also repairs exisiting instruments. He does not have a welding kit and all implements and tools are completely manual which includes a variety of fogging hammers, anvil, blower and the furnace. An interesting aspect is the use of a different kind of forging hammer as compared to the conventional ones used in the cluster. This design apparently gives a better finish and is locally made by blacksmiths in the neighbouring state of Maharatshtra.

He has practised New product development through Suruchi trust’s interven-tions and efforts to popularise new designs, as as improve the quality of existing implements.

Main Isuues:



Development of a display stand to exhibit wares

Jigs and fixtures that assist in filing and finishing of the instruments


No packaging or arrange-ment to carry many tools at one go

No packaging or arrange-ment to carry many tools at one go

Ackward working postures cause long term occupational injuries

Product improvemnets are needed spaciically with finish-es, new designs and handles








Ackward placement of hand operated-blower is likely to cause occupational stress and pain. The blower hould be placed closer.

The wall space at the back could be used as a display / storage space. It is currently unused.

Low seating must be replaced with ergo-nomic seating

Sonirao Gonia

Sonirao Jiyabhai Gonia is a resident of Mukam post Jarada, Taluka Ahwa, Zilla Dang, Gujarat.

He is a tribal who belonged to a family which practised agriculture for a living. His father is a farmer. Sonirao became a blacksmith as a means of steady income in lean periods of agriculture. He trained for 4-5 months and has been a practis-ing blackmith for 7 years. Sonirao workis in the fields during the sowing and cut-ting seasons and works as a blacksmith during the offseason.

The shop is run by his wife and himself. Sonirao does not reach out to customers by selling his wares outside, rather most customers are the walk in types. His an-nual turnover is around 50,000 a year.

He normally makes sickels, axes and other small cutting instruments, and he also repairs exisiting instruments. He does not have a welding kit and all implements and tools are completely manual which includes a variety of fogging hammers, anvil, blower and the furnace.

An interesting aspect is the use of a different kind of forging hammer as com-pared to the conventional ones used in the cluster. This design apparently gives a better finish and is locally made by blacksmiths in the neighbouring state of Maharatshtra. Sonirao purachased ithe set of hammers from a cluster on the border. Two different sizes (as seen in image on the left) are available for Rs.600 and larger for Rs.900.


Main Isuues:




No display / other visible marketing points, so most promotion is through work of mouth only


Weildinga heavy hammer in this position is likely to cause sever lumbar stress Open coal furnaces causes inhala-

tion of carbon monoxide and CO2, leading to im paired respiratory function

PLow seating and specifically sitting on unergonomic seating for long periods leads to

sever back pain in later years









Chinubhai Dabke

Chinubhai Guljibhai Dabke is a resident of Mukam post Jarada, Taluka Ahwa, Zilla Dang, Gujarat.

He is a tribal who belonged to a family which practised agriculture for a living. His father is a farmer. Sonirao became a blacksmith as a means of steady income in lean periods of agriculture. He started with no formal training and has been a practising blackmith for 7 years. Chinubhai was helped by the Suruchi trust, Vagai trust and he was greatly assisted by the government subsidy which allowed him to procure basic tools of the trade.

Chinubhai retails his wares in the saturday market & his annual turnover is around 50,000 a year.

He normally makes sickels, axes and other small cutting instruments, and he also repairs exisiting instruments. He does not have a welding kit and all implements and tools are completely manual which includes a variety of fogging hammers, anvil, blower and the furnace. An interesting aspect is the use of a different kind of forging hammer as compared to the conventional ones used in the cluster. This design apparently gives a better finish and is locally made by blacksmiths in the neighbouring state of Maharatshtra.


Main Isuues:




Jigs and fixtures that assist in filing and finishing of the instruments


Anvil and tools need to be of better quality for better finishes in products









Low seating and specifically sitting on unergonomic seating for long periods leads to


Khalapbhai Kokani

Khalpabhai Ramubhai Kokani is a resident of Danadhar village, Nichlu fadiya, Taluka Vyari, Zilla tapi.

He is a tribal who belonged to a family which practised agriculture for a living. Khalpabhai became a blacksmith as a means of steady income in lean periods of agriculture. He has been a practising blackmith for 15 years. Sonirao workis in the fields during the sowing and cutting seasons and works as a blacksmith during the offseason. His family owns 2 bigha of land with plenty of water and he culti-vates groundnut cash crop.

Khalpabhai does not reach out to customers by selling his wares outside, rather most customers are the walk in types. His annual turnover is around 25,000 a year.

He normally makes sickels, axes and other small cutting instruments, and he also repairs exisiting instruments. He does not have a welding kit and all implements and tools are completely manual which includes a variety of fogging hammers, anvil, blower and the furnace. He also makes the chula, plaughs and other tongs in addition to the other irregular implements.


He suffers from intense shoulder and back pain, which often impedes his work.

Main Isuues:





Design of better tools is needed to improve produc-tivity and releieve occupa-

tional fatigue

Improvement in product construction and finishes is

needed








Amitbhai Panchal

Amitbhai Manharbhai Panchal owns and runs Shivshakti Iron works and resides in Buhari, behind Gujarat School, Unnai Road, Valod, District Tapi, Gujarat.

The main product range includes agricultural implements such as sickles, hoes, spades, plougher, de weeder, axes and is currently involved in building several custom designed implements such as seeders, deweeders etc. His main activities are blacksmithy & fabrication.

The annual turnover is 6 lac rupees. Amit Panchal is a respected blacksmith whose products are in high demand. Amit’s shop is the best laid out, as com-pared to all units surveyed. The tools are neatly classified, the finished goods are beautifully displayed. He maintains a safety stock level of 3000 sickles and 3000 small slicers at all points of time. He regularly sells out because of the demand for his quality.

Of all the blacksmiths surveyd, Amitbhai Panchal appears the most innovative and versatile. He has innovated several implements to increase the efficency or reduce manual labour. He has designed an edge cutting machine, which cuts serrations on the edge of sickles, reducing the time from around 15 minutes of manual cutting to less than a minute.

He exhibits a keen sense to understand and appreciate design as an enabler. He is eager to participate in design training / programes that could help in upgrada-tion.

Main Isuues:

Low workstation for forging is leading to fatigue, back troubles and other physi-cal problems.

Lack of technical design inputs for bigger agricultural machinery.






Product design help for design of larger agricultural machinery and implements. Technical assistance in manufacturing principles and marketing.

Advertising and promotion of products made, through government assisted schemes

Design of prochure / leaflet

Higher level of inter cluster communication for better design and promotion

Design of a logo, which would help in brand positioning and promotion


Nileshbhai Panchal

Nileshbhai Panchal Is a resident of Sarbhon, taluka Bardoli, Surat district and owns Shiv Shakti Engineering Works.

The main product range includes agricultural implements such as sickles, hoes, spades, plower, deweeder, axes etc. His main activities are blacksmithy and weld-ing. Nileshbhai’s annual turnover is 200,000 rupees. His small shop is self owned and has cutting machine, welding machine, drill and grinding machines in his shop. He employs 3 people.

Nileshbhai’s main problems range from availability of coal to unavailability of labour. He employs tribals who he claims, are notorriously unreliable.

Nileshbhai’s main line of work in welding and fabrication, rather than blacksmithy. Bad ergonomic postures were observed. Nileshbhai confirms sever back and shoulder pain as well as nasal allergy.

There is no branding of ny kind.

He sells his wares to the Kamrej wholesale market which further retails the prod-ucts. He confesses to very low deman for his products in blacksmithy.

Main Isuues:

Like most blacksmiths in the area, Nileshbhai’s layout around the kiln is cramped, haphazard and unergonomic. He confesses to extreme back and knee pain dur-ing work.

Lack of safety equipment whilst using welding was observed and documented. This could lead to loss of vision and other vision disorders in the near future.

Product finishes need major improvement.

Surface finishes of the products need radical

improvement

Cramped, ill designed layout impedes work

efficiency




Lack of safety gear of right

specifications

Open coal furnaces causes inhalation of carbon mon-oxide and CO2, leading to im paired respiratory function

Low cramped seating




Jigs and fixtures for ease of working and productivity enhancement



3.0OCCUPATIONAL ERGONOMICS


Human factors and Ergonomics (HF&E) is a multidisciplinary field ofthe study of designing equipment and devices that fit the human body and human cognitive abilities. The International Ergonomics Association de-fines ergonomics or human factors as “Ergonomics (or human factors) is the scientific discipline concerned with the understanding of interactions among humans and other elements of a system, and the profession that applies theory, principles, data and methods to design in order to optimize human well-being and overall system performance”.

Ergonomics has influences from disciplines in its study of humans and their environments, including anthropometry, biomechanics, mechanical engineering, industrial engineering, industrial design, information de-sign, kinesiology, physiology and psychology. To assess the fit between a person and the used technology, human factors specialists or ergonomists consider the job (activity) being done and the demands on the user; the equipment used (its size, shape, and how appropriate it is for the task), and the information used (how it is presented, accessed, and changed).

Human factors is an critical discipline that focuses on safety and produc-tivity of the human being through the design of objects, surroundings and others. Proper ergonomic design is necessary to prevent repetitive strain injuries and other musculoskeletal disorders, which can develop over time and can lead to long-term disability. Human factors and ergonomics is concerned with the ‘fit’ between the user, equipment and their environ-ments. It takes account of the user’s capabilities and limitations in seeking to ensure that tasks, functions, information and the environment suit each user.

OBSERVED ERGONOMIC ISSUES

POSTURE OF WORKINGThere are 2 recommended posititons for blacksmith. One is the standing

position and the other is the sitting position. The height of the placement of the anvil is calculated at the knuckle heingth of the blacksmith when standing erect. When sitting the anvil height should correspond with the height of the knees.


VENTILATIONThe forge should be outfitted with a chimney to properly vent smoke, fumes and ash. Improper ventilation of carbon monoxide, smoke, ash and

One of the most critical tools of the blacksmith - the hammer is im-protant. injuries or use of an extra heavy hammer include carpal tunnel syndrome, tendonitus in the wrist, elbow and shoulder, damaged cartilage, and torn ligaments. Some blacksmiths prefer short handles on their ham-mers. However to achieve a heavier blow, either a heavier hammer head or heavier blows must be used with this shorter handle. A longer handle when held at the end will provide more velocity, thus more impact. The

handle length should equal the distance from the bottom of the hammer head to the inside of blacksmith’s elbow. The handle should be custom-ized to fit the user’s hand by rasping. Some blacksmiths trim down the first 3-4 cm beneath the hammer head to provide some flex to the handle, which absorbs some shock from the impact.

HEIGHT OF THE FORGEThe height of the forge should be what is comfortable for the user. Stoop-ing should be avoided. Modifying the legs of the forge will create the perfect forge height.

There should be enough space on the forge hearth to conveniently hold a few tools for the task at hand. The workspace should not be cluttered. Another surface to hold additional tools should be near the anvil.


soot can cause chronic health problems, even death. Exhaust must be removed from the room completely. The position of the anvil to the forge is generally at a 90 to 180 degree angle from the forge, and about 1 to 2 steps away from the forge.

HEIGHT OF THE FORGEThe vise can be at 90 to 180 degrees from the forge, and also 1 to 2 steps away from the forge. The slack tub should be in close proximity to the station, and convenient to quenching hot bars of iron. It should be large enough to quench a bar for safe handling. It should be of non-flammable

PLACEMENT OF ANVILThe anvil should be placed on a solid and secure base. Some anvil bases are buried as much as three feet into the ground. If the anvil base is not buried or anchored to the floor, make sure the anvil does not rock, slide or pitch.

13


4.0KEY OBSERVATIONS


Key Observations

1The region of south Gujarat diplayes an interesting dichotomy - whereas Surat the main city in this region is one of the richest on account of it be-ing a diamond cutting hub, the nearby areas are completely dependent on agriculture and local crafts. The region of Dangs, bordering Navsari is a tribal belt which has a very different socio economic and socio cultural equation. The region’s blacksmiths belong to 2 communities: Panchals who are tranditional blacksmiths and tribals - who have adopted this as a profession. Through the survey it was noticed that panchals are by nature entrepreneurs whereas tribals preferred to work on wages. The panchals consider the tribals to be unreliable and show a deep distrust towards their practices. the youth of the area possess a very low level of education and technical skills are absent. Iliteracy and lack of information on avail-able government schemes, coupled with the lucre of diamond cutting and polishing in nearby Surat as well as minimal income from blacksmithy, a lot of youth have migrated, leading to a total glut of manpower. The revival of this cluster is important to maintain and nurture the delicate balance between agriculture and blacksmithy which caters to this need.

2Upon a detailed study of the cluster it has been noted that almost all the units documented use manual processes to shape the metal into imple-ments. The manual method is labour intensive; often following the tra-ditional method of metal working followed from centuries. This manual method is crude, labourious, resulting in inconsistent quality and low volumes of production.

3All the units produce the same implements and thus internall compete

for the small and decilining markets in south Gujarat. There is exposure to other markets in nearby cities as the most of the production is consumed in the same geographical area.

4 Most units look to differentiation through addition of additional capabili-ties such as welding, which gives them access to fabrication jobs of the surrounding areas. These fabrication jobs are for grills, gates and shutters in the developing real estate markets around.

5There is a distinct vulnerability that similar looking, cheaper, mass pro-duced products might enter the market through dumping, thereby wiping out the native industry. The products produced by these blacksmiths all look the same, are similarly priced. This leads to a ‘commonisation’ of all products, and creates no product differentiation.

6he entire cluster is a unorganised one, where production, labour manage-ment and time management are serious issues of reckoning.

7There is absolutely no standardisation of designs, as the individual black-smiths follow what they have learnt earlier. These small lots are produced in batches and the production volumes are low. Suruchi Sakshat Vasahat Traust has been working and has attempted to standardize through mate-rial allocation, dimensional coherence and skill upgradation through train-ing. They supply good quality raw material and buy back the produced goods.

8The working area of most units are a matter of concern. The workstation layout needs to be approached from a scientific and human factors per-

spective, taking into account the sitting and working postures; such that minimal effort is exerted by the blacksmith. The working conditions also need improvement through various factors such as adequate illumination and ventilation. Burning coal emits carbon dioxide and carbon monoxide in large quantities. Carbon Monoxide is toxic and over a aperiod of time, reduces the capacity of the lungs for oxygen absorption. This often leads to respiratory illnesses such as tuberculosis. Back pain and fatigue has been confirmed by almost all respondents. By the design of workstations that take into account better working psotures, this fatgue can be allevi-ated and thus the productivity of the artisan increases.

9The main product line being agriculturltural implements nd machinery, the demand and supply of these instruments varies with the sowing and reap-ing seasons. The implements change as well. The sales of the implements are dependent on this cycle wherein the sales are iregular, and a mojority of the period, the implement is sharpened repeatedly or repaired. Hence the income of the blacksmith is dependent on this phenomenon. They often do not have consistent work throughout the year. Labour charges provided to the workers or the profit margin very low. The blacksmith calculates the cost of services depending on place and other factors. For e.g. the cost of sharpening of sickle is around Rs.20.

10Doing only order work, decreased market orders and insistence of local users for traditional designs often does not encourage product innovation. The blacksmiths are unable to innovate, improve, refine their work in a radical manner.

11Understanding of business, costing, management is nil. The blacksmith sometimes ends up selling their products at minimum margin or at the cost rate. Lack of awareness about education, technology, work environ-ment and health consciousness are major issues. Low / no motivation for

further development has been witnessed in many survyed blacksmmiths, who are unable to keep with the changing times.

12The raw materials namely mild steel or carbon steel is procured from local traders. There is no consistencvy of material. the main way of testing to test the malleability by bending a strip - if the strip bends easily it means that steel is of moderate quality. Hard steel means that it is brittle and it would be very difficult to work. There is no consistency and the final prod-uct of the blacksmith if often dependent on the raw material.

13At a cluster level, there is a requirement of a common facility center which could help the blacksmiths in terms of material testing and certification, material bank, design, training and promotion of products.

14The design of the implements is hundreds of year old, and has hardly changed. It has also been reported that the local consumers often reject new designs or innovations, and hnce the blacksmiths prefer to make the same designs as before. Also, there seems to be a complete lack of awareness of new designs and techniques developed in other parts of the country, as inter cluster comminication and networking is completely ab-sent. Exposure to creativity, design thinking to improve and develop new products to cater to current market demands is an immediate require-ment. Vocational training to make accessories, jewellery and/or small utility products to create and provide employment during monsoons or lean seasons, with adequate marketing capabilities is also

15Awareness and exposure of modern techniques and processes requiredwith Technical training, skill up gradation and skill refinement trainings from time to time. The workshops should also ocus on the occupational injuries and an awareness and training of comfortable work postures to


reduce physical strain. has to be inculcated.

16There is a visible monotony in the entire product range of the cluster. Mar-ket penetration difficult without product variety and range. There is a need for diverse range of products as per contemporary market demands, spe-cifically in other parts of the copuntry or state even. The product range, specific to the end user needs, usage and purpose should be developed.

17Visual identity, branding, marketing support required in almost all cases as the products are virtually indistinguishable from each artisan to other. De-velopment of a common (cluster) brand instead of multiple brands is also an immediate requirement. This cluster branding gives rise to visibility.

18Better displays and retail outlets required to showcase products. More efforts to popularise the products such as organised weekly markets, a nodal sales center or sales in nearby towns and sectors should also be done.


5.0DESIGN WORKSHOP REPORT


SESSION 1INAUGURATION & INTRO TO BLACKSMITHY

31.01.2013 / Session 1 / 11-13:00 hours

The workshop commenced with a small inugration and presentation of

memntos to the designer by Shri RamKumar Singh and Smt Rama Ben.

Invoking the spirit of Gandhian philosophy, Mr.Singh spoke at length on

the formation of the cluster, history and the problems encountered till

date.

He stressed upon the fact that the humble blacksmith was a very vital

link in the agrarian cycle and without his services, no farming community

could exist.

He also exorted upon the participants to come forth with their problems,

resolve their differences and present a unite front for solution of the

problems.


SESSION 2DESIGNCLINICS SCHEME: PROVISIONS & BENEFITS

31.01.2013 / Session 2 / 13.00 - 14:00 hours

SESSION 4DISCUSSIONS: PROBLEMS OF BLACKSMITHS

01.02.2013 / Day 2 / 10.00 - 12:00 hours

SESSION 3 PRESENTATION OF NAS REPORT

31.01.2013 / Session 3 / 15.00 - 17:00 hours

SESSION 5 OCCUPATIONAL ERGONOMICS

01.02.2013 / Day 2 / 13.00 - 15:00 hours

The second session of day 1 was dedicated to the explaining in detail the

provisions and implications of the Design Clinics scheme. The benefits,

motives and objectives were explained in detail. Several participants

wanted detailed information and the session was full of questions and

answers.

Issues addressed in this session were the redesign of the workstation and

tools. Using the existing furnace as a practical example, practical changes

were made on he spot to demonstrate the principles of workplace ergo-

nomics. Issues such as smoke inhalation, primary and secondary reach,

seating and curvature of spine, handtools dampening were suggested

and practically demonstrated.

Session 3 of day 1 was dedicated to the comprehensive presentation of

the Need assessment done, methods used and implications of the analy-

sis.

Session 1 of day 2 was focussed on the discussions of specific and generic problems in the region for blacksmithy. The participants actively partici-pated with several questions. The main questions that were discussed were:

Introduction of mechanisation in the process: can we mould sickles? If so what’s the smelting and other issues? What’s the melting point of steel in agri instruments? Is this MS or carbon steel?Forging / moulding / furnace temp controlMechanise the forging hammerMechanise the grinding and serrations


SESSION 6 STRATEGIES FOR SMALL BUSINESSES: RUPAL SHAH

01.02.2013 / Day 2 / 15.00 - 17:00 hours

SESSION 7 NEW TECHNOLOGY DEMONSTRATION: RAMABEN

02.02.2013 / Day 3 / 10.00 - 12:00 hours

Rupal Shah, a motivational trainer from the Junior Chamber International,

Bardoli presented a seminar on improving business through positive

thinking and application of generic management principles.

Smt. Ramaben demonstrated the newly developed charcoal making

method which has been indigeneously developed at SSVT to the partici-

pants. Using locally available twigs and dried leaves, charcoal pellets can

be made through controlled burning, powdering, mixing with resin and

extruding as pellets. The whole cycle was demonstrated to convince the

participants to adopt the new method, which promises to address a huge

issue of charcoal availability in the region.


SESSION 8 PRODUCT DESIGN & PROCESS IMRPOVEMENTS

02.02.2013 / Day 3 / 12.00 - 14:00 hours

SESSION 9 VISIT TO MN AGRO

02.02.2013 / Day 3 / 15.00 - 18:00 hours

SESSION 10 INDIVIDUAL UNIT DISCUSSIONS

03.02.2013 / Day 4 / 10.00 - 17:00 hours

Session 8 was a detailed case study presentation into new product

development which is non technology based; rather purely human need

based. Using examples and case studies, design thinking or problem

solving with self-help methods were demonstrated through group duis-

cussion, live drawing and other methods which enforced that Product

design is the creation of objects of utilitarian value to people. Products

function as part of larger systems, and the product designer’s role is con-

stantly growing as she/her understands the larger implications of prod-

ucts, and the relationships with users.

MN AGRO is a promising rural entrepreneur who specialises in the manu-

facture of weeders, mini tractors and other agricultural equipment. A fac-

tory visit was organised as a fact finding mission to understand if there

were any immediate project opportunities.

The final day was dedicated to the discussions and immediate design

solutions to the blacksmith community present. The main solutions were

provided in the improvement through workplace ergonomics and quality

of output.

Individual sessions were held with Jayantibhai Panchal, Dipeshbhai Pan-

chal, Kishanbhai Gamit, Diplipbhai Panchal, Vasantbhai Kokani, Sonirao

Gonia, Chinubhai Dabke & Ishwarbhai Panchal amongst several others.

Questions ranging from production, design, marketing and other issues

were addressed.


PROJECT OPPORTUNITIES

Projects:

1. Low cost manual charcoal maker

2. Ergonomic furnace for blacksmiths

3. Ergonomic working hand tools set for blacksmiths

4. New product possibilities for agriculture through blacksmithy

Documents

BLACKSMITHS OF BARDOLI - designclinicsmsme.orgdesignclinicsmsme.org/Design Awareness Programme Reports... · BLACKSMITHS OF BARDOLI NEED ASSESSMENT SURVEY ... All employees of the